Interior wall construction

ABSTRACT

An interior wall system includes one or more wall panels configured of a foam material, such as, for example, expanded polystyrene. Interior wall studs are positioned between adjoining wall panels. One or more track plates is also configured to engage the one or more wall panels at the top and bottom of the one or more wall panels.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 60/809,627, filed May 30, 2006, entitled, “Interior Wall System,” which is incorporated herein by reference. In addition, the present application is related to U.S. patent application Ser. No. ______, attorney docket no. 1006.U02, entitled “Exterior Wall Construction,” filed May 29, 2007; U.S. patent application Ser. No. ______, attorney docket no. 1006.U04, entitled “Column and Beam Construction,” filed May 29, 2007; and, U.S. patent application Ser. No. ______, attorney docket no. 1006.U05, entitled “Floor and Roof Construction,” filed May 29, 2007.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

Embodiments of the present invention relate generally to construction materials. More particularly, embodiments of the present invention relate to construction using foam materials.

2. Related Technology

Polystyrene, a polymer discovered in the nineteenth century, is a highly useful material having a wide variety of applications that is manufactured for use in numerous commercial enterprises. One of the most common uses of polystyrene, however, is expanded polystyrene, which is used for making such products as packing material, craft and model materials, and take-away food cups and containers.

In addition to these uses, expanded polystyrene is one of several foams used in making insulated panel building materials. These building materials, also referred to as insulated concrete forms, are used to form molds for use in constructing walls of buildings. Most commonly, an insulated concrete form for a portion of wall is set in place and the concrete is then poured into the insulated concrete form. The form then remains in place, where it acts as insulation both for curing the concrete and as general insulation for the building or structure being constructed.

Using foams for building construction provides numerous benefits. For example, foams serve as excellent insulators helping to reduce energy costs. Foams also provide superior sound absorption and their use contributes to fast construction of buildings, thereby creating competitive costs for using foams when compared to conventional building methods such as wood framing. These benefits have led to increased use of foams in building certain portions of buildings, such as exterior walls built using insulated concrete forms.

Although foams are used extensively in manufacturing insulated concrete forms for exterior walls of buildings and other structures, use of foams for other building systems and materials is not widespread. What is needed are systems and methods for configuring expanded polystyrene for interior walls of buildings and other structures.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention include an interior wall system including wall panels made of foam material, such as, for example, expanded polystyrene. In one embodiment of the invention, the wall panels are configured to be interlocking. Moreover, the wall panels may be configured to create a wall having any length, width, height, and shape. The wall system is also characterized by the use of wall studs to hold wall panels in place and to provide increased stability and security of the wall panels.

These and other aspects of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other aspects of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings are not drawn to scale. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 shows a wall panel; and

FIG. 2 shows an interior wall system.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the present invention relate to systems and methods for interior walls made of foam materials, such as, for example, expanded polystyrene (“EPS”) material. The insulating interior wall system of the present invention, and methods of making the same, provide a lightweight to heavyweight structural design incorporating steel stud gauges and foam wall panels. Embodiments of the present invention thus provide a high standard of sound insulation for an interior wall and are designed and configured to accept any number of finishes, including, but not limited to, plaster and drywall.

With attention now to FIG. 1, a wall panel 100 of an interior wall system is shown. In one embodiment of the invention wall panel 100 may be configured of any foam material, such as, for example, EPS-cement composites, polystyrene foams such as expanded polystyrene and extruded polystyrene, and polyurethanes.

In addition, wall panel 100 includes top 102 and bottom 104, as well as first end 106 and second end 108. First end 106 includes receiving portion 110, while second end 108 includes protruding portion 112. In one embodiment of the invention receiving portion 110 is a groove extending along the height, A, of wall panel 100. Similarly, in one embodiment of the invention protruding portion 112 is a protrusion extending along the height A of wall panel 100.

In one embodiment of the invention where multiple wall panels are configured in an arrangement to create an interior wall having any length, width, height, and shape, receiving portion 110 of first end 106 may receive a protruding portion of a second wall panel (not shown). Likewise, a receiving portion of a third wall panel (not shown) may receive protruding portion 112 of second end 108. In this way embodiments of the present invention provide an interior wall system where multiple wall panels may be configured and arranged to substantially connect to each other to form an interior wall having any length, width, height, and shape.

With attention now to FIG. 2, an interior wall system 200, having wall panels 202, 204, and 206, is shown. In one embodiment of the invention, wall panels 102, 104, and 106 are made of any type of foam, such as, for example, EPS-cement composites, polystyrene foams such as expanded polystyrene and extruded polystyrene, and polyurethanes. Although wall panels 202, 204, and 206 are shown in FIG. 2, it is to be appreciated that any number and configuration of wall panels of interior wall system 200 is possible and incorporated by embodiments of the present invention. Wall panels 202, 204, and 206 are configured to be arranged to form an interior wall system having any length, width, height, and shape. Moreover, individual wall panels 202, 204, and 206 may have any thickness depending on the design needs of the interior wall structure.

While wall panels 202, 204, and 206 may have any thickness, each of wall panels 202, 204, and 206 includes a receiving portion and a protruding portion. More particularly, wall panel 202 includes receiving portion 208, located at a first end of the wall panel 202, and a protruding portion 210, located at a second end of the wall panel 202. Wall panels 204 and 206 include similarly situated receiving portions and protruding portions, although only receiving portion 212 of wall panel 206 is shown in FIG. 1.

In addition to wall panels 202, 204, and 206, interior wall system 200 also includes interior wall studs 214, 216, and 218. In one embodiment of the invention interior wall studs 214, 216, and 218 are made of metal, such as, for example, galvanized steel. Each of interior wall studs 214, 216, and 218 is configured to engage receiving portions and protruding portions of wall panels 202, 204, and 206. For example, interior wall stud 216 is configured to engage protruding portion 210 of wall panel 202 and receiving portion 212 of wall panel 204.

Finally, interior wall system 200 also includes plate tracks 220 and 222, which attach to the top and/or bottom, respectively, of wall panels 202, 204, and 206. In one embodiment of the invention plate track 220 substantially surrounds the top of wall panels 202, 204, and 206, while plate track 222 substantially surrounds the bottom of wall panels 202, 204, and 206. Also, in one embodiment of the invention track plates 220 and 222 engage ends of wall studs 214, 216, and 218. Moreover, in one embodiment of the invention, plate tracks 220 and 222 are made of metal, such as, for example, galvanized steel. It is to be appreciated that plate tracks 220 and 222 can be of any length and can vary dimensionally according to design specifications for specific structural implementations.

In operation, wall panels 202, 204, and 206 are placed in plate track 222, with plate track 222 being attached to a floor or flooring system. Interior wall studs 216 and 218 are placed between wall panels 202, 204, and 206, with protruding end 210 of interior wall panel 202 engaging interior wall stud 216. Interior wall stud 216 also engages receiving end 212 of wall panel 204. Further, interior wall stud 214 engages receiving end 208 of wall panel 202. In addition, plate track 220 is placed on top of wall panels 202, 204, and 206, thus covering wall panels 202, 204, and 206, as well as interior wall studs 214, 216, and 218. Interior wall system 200 is further configured to accept any design finish, such as, for example, plaster, drywall, and other finishes. Interior wall system 200 thus provides a system for building interior walls providing enhanced insulation and an easy and effective method of installation and manufacture.

In one embodiment of the invention interior wall system 200 may be used in conjunction with other building systems incorporating the use of foam materials into building construction. In this way interior wall system 200 may be part of a building and construction system that uses foam materials along with other components to construct interior and exterior components of buildings.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. An interior wall system, comprising: one or more wall panels; one or more wall studs configured to engage the one or more wall panels; and one or more track plates configured to engage the one or more wall panels.
 2. The wall system as recited in claim 1, wherein each of the one or more wall panels further comprises a protruding portion and a receiving portion.
 3. The wall system as recited in claim 2, wherein the protruding portion of each of the one or more wall panels is configured to engage the receiving portion of each of the one or more wall panels.
 4. The wall system as recited in claim 2, wherein the one or more wall studs are configured to engage the protruding portion and the receiving portion of the one or more wall panels.
 5. The wall system as recited in claim 1, wherein the one or more wall panels are comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene.
 6. The wall system as recited in claim 1, wherein the one or more wall studs is comprised of one or more of: steel; galvanized steel; or, any other metal.
 7. The wall system as recited in claim 1, wherein the one or more track plates is comprised of one or more of: steel; galvanized steel; or, any other metal.
 8. The wall system as recited in claim 1, wherein the one or more track plates engages the one or more wall panels at a top or a bottom of the one or more wall panels.
 9. The wall system as recited in claim 7, wherein the one or more track plates engage the one or more wall studs.
 10. An interior wall system comprising: one or more wall panels, wherein each of the one or more wall panels includes a first end and a second end, the first end having a receiving portion configured to engage a protruding portion of the second end such that a first wall panel and a second wall panel can be substantially connected when the second end of the second wall panel is engaged by the first end of the first wall panel; one or more wall studs, wherein each of the one or more wall studs is configured to be positioned between the second end of the second wall panel and the first end of the first wall panel and is configured to engage the receiving portion of the first end of the first wall panel and the protruding portion of the second end of the second wall panel; and one or more track plates, wherein each of the one or more track plates is configured to attach to a bottom or a top of the one or more wall panels and is configured to substantially surround the bottom or the top of the one or more wall panels.
 11. The wall system as recited in claim 7, wherein the one or more wall panels are comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene.
 12. The wall system as recited in claim 7, wherein the one or more wall studs are comprised of one or more of: steel; galvanized steel; or, any other metal. 